Flexible led display having an optic optically coupled with an led chip

An LED display comprising:

• an LED chip configured to emit light about a focal axis;
• a circuit board configured to selectively electrify the LED chip, wherein the circuit board is elastically deformable;
• and
• a collimating optic molded onto the LED chip as a unitary encapsulating structure that is elastically deformable, the optic comprising a mold-in-clear (MIC) material and defining an optical axis, wherein the optical axis and the focal axis maintain alignment when the circuit board is positioned in a non-planar orientation.

A method for manufacturing a LED display, the method comprising:

• producing a flexible circuit board substrate;
• mounting an LED chip configured to emit light about a focal axis on the flexible circuit board substrate;
• and
• molding a collimating optic formed from an optical-grade flexible material onto the LED chip and adjacent portions of the flexible circuit board substrate to form a unitary encapsulating structure that is elastically deformable, the optic defining an optical axis,
• wherein the optical axis and the focal axis maintain a generally aligned position when the circuit board is positioned in a non-planar orientation.

A vehicle LED display comprising:

• an LED chip configured to emit light about a focal axis;
• a circuit board configured to selectively electrify the LED chip, wherein the circuit board is elastically deformable and comprises a plurality of conductive layers separated by respective substrate layers, wherein the conductive layers and the substrate layers, in combination, define a first thermal via and a second thermal via extending through the conductive layers and the substrate layers, wherein the first thermal via and the second thermal via each include an interconnect and a filler material disposed adjacent to the interconnect, the first thermal via and the second thermal via configured to dissipate heat generated by the LED chip;
• and
• an optic optically coupled with the LED chip and defining an optical axis, wherein the optic is elastically deformable, and wherein the optical axis and the focal axis maintain a generally aligned position when the circuit board is positioned in a non-planar orientation.